Flexible Display Roll-to-Roll Carrier Substrate Transfer
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
The roll-to-roll method for manufacturing flexible display devices is limited by substrate deformation during processing, which hinders efficiency and convenience in substrate transfer, and existing solutions that use carrier substrates have not been effectively applied to this method.
Innovation Solution
An apparatus and method that attach a flexible substrate to a carrier substrate, followed by a roll-to-roll bonding process using a substrate transferring part, separating part, upper bonding part, and lower bonding part to form device layers and patterns, allowing for efficient separation and reuse of the carrier substrate.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If the roll-to-roll method is applied to manufacture flexible display devices, then productivity is improved, but substrate deformation occurs during processing
Solution Approach 1:
A carrier substrate is introduced as an intermediary support during the roll-to-roll manufacturing process. The flexible substrate is attached to this rigid carrier substrate, which prevents deformation while allowing continuous processing. After manufacturing, the flexible substrate is separated from the carrier substrate, enabling both high productivity and shape stability.
2Shape
If the flexible substrate is attached to a carrier substrate to prevent deformation, then substrate shape stability is improved, but device complexity increases
Solution Approach 1:
The carrier substrate serves as a temporary support that is discarded after serving its purpose. It is used only during the manufacturing process to maintain substrate shape, then separated and removed after the flexible substrate is complete, simplifying the final product while maintaining process stability.
3Ease of operation
If the carrier substrate method is applied to the roll-to-roll process, then substrate transfer convenience is improved, but process complexity increases
Solution Approach 1:
The carrier substrate integrates multiple functions into a single component: it serves as a support structure, a transfer medium, and a handling platform. By combining these functions, the system achieves convenient substrate transfer through the roll-to-roll process without requiring separate mechanisms for each function, thus reducing overall process complexity.
Data Source
AI summary
An apparatus and method for manufacturing a flexible display device by a roll-to-roll method, are discussed. According to an embodiment, the apparatus includes a substrate transferring part for transferring a lower substrate attached onto a carrier substrate; a substrate separating part for separating the carrier substrate from the lower substrate transferred by the substrate transferring part; an upper bonding part for bonding an upper substrate to an upper surface of the lower substrate from which the carrier substrate is separated; and a lower bonding part for bonding a rear substrate to a lower surface of the lower substrate from which the carrier substrate is separated.